Three-phase coupled multidirectional synergistically enhanced composite honeycomb structure and energy absorption device

Abstract

The invention discloses a three-phase coupled multidirectional synergistically enhanced composite honeycomb structure and an energy absorption device. The three-phase coupled multidirectional synergistically enhanced composite honeycomb structure comprises a honeycomb base body formed by a plurality of polygonal three-dimensional honeycomb cell elements which are closely and regularly arranged, a configuration reinforcement body with a three-dimensional geometric gap configuration, and an interface coupling reinforcement body. Wherein the honeycomb base body, the configuration reinforcement body and the interface coupling reinforcement body form a three-phase coupled integrated composite core body through the multi-phase interface. According to the composite core material structure, a honeycomb structure serves as a base body, discontinuous thin-wall components with controllable structures are embedded into pores of the honeycomb structure to serve as reinforcing phases, and in-situ filling and curing are conducted through foam materials. By means of the three-phase coupling structural design, collaborative enhancement of the honeycomb, the thin-wall component and the foam material in the out-of-plane and in-plane directions is achieved, and the overall comprehensive mechanical property is remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of energy-absorbing materials, and in particular to a three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure and an energy-absorbing device. BACKGROUND

[0002] The honeycomb structure has become the core core of sandwich structures in the fields of aerospace, rail transportation, automobile engineering, etc., the key component of energy-absorbing devices, and the preferred material for high-performance interiors and packaging, due to its excellent specific strength, specific stiffness and energy absorption capacity.

[0003] However, the existing applications expose at least the following three significant defects of the honeycomb structure:

[0004] Firstly, the out-of-plane performance bottleneck: under compression load, the out-of-plane direction has high strength, high stiffness and stable progressive collapse energy absorption characteristics (cell wall plastic folding forms a platform energy absorption stage), but the performance is limited by the wall thickness, material properties and single deformation mode, which is difficult to meet the demand of extreme complex working conditions. Secondly, the in-plane performance short board: under shear or compression load, due to the lack of continuous support, the load transfer depends on the sliding, stretching or local rotation between cell walls, and the energy absorption mechanism is mainly the inefficient intercellular shear sliding, local peeling and wall bending, resulting in the near absence of in-plane strength, stiffness and energy absorption capacity; the huge gap in mechanical properties of such honeycomb in different directions limits the application of honeycomb in more complex stress environments. Thirdly, insufficient space utilization: the internal cavity formed by the continuous thin-walled skeleton occupies a large amount of space but does not participate in force and energy absorption, which limits the upper limit of overall performance and aggravates the weakness of in-plane direction support.

[0005] In summary, the core contradiction of breaking through the performance of the honeycomb focuses on two points: one is to improve the upper limit of the out-of-plane performance to cope with high load impact, and the other is to bridge the huge gap between the in-plane and out-of-plane performance to adapt to the multi-directional complex stress environment, and fully utilizing the internal space of the cell becomes the key path to solve the contradiction. SUMMARY

[0006] The present application provides a three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure and an energy-absorbing device to solve the technical problems of the performance imbalance of the existing honeycomb structure in the out-of-plane and in-plane directions, the insufficient utilization of the internal space, and the hindering of its wide application in multi-directional complex load working conditions.

[0007] In view of the above technical problems, the present application provides a three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure, comprising:

[0008] The honeycomb base is composed of a plurality of tightly arranged polygonal three-dimensional honeycomb cells, each of which has a cell.

[0009] The configuration reinforcement body has a three-dimensional geometric gap configuration, the length of the configuration reinforcement body is equal to the length of the honeycomb cell, and the cross-sectional profile of the configuration reinforcement body is smaller than the inscribed circle of the cell of the honeycomb cell; the configuration reinforcement body is embedded in all the cells or in part of the cells in a regular layout;

[0010] The interface coupling reinforcement body fills the gap between the inner wall of the cell and the configuration reinforcement body by in-situ foaming curing, and all the gaps of the configuration reinforcement body itself, forming a continuous multiphase interface;

[0011] The honeycomb matrix, the configuration reinforcement body and the interface coupling reinforcement body form a three-phase mutual coupling integrated composite core through the multiphase interface.

[0012] Optionally, the interface coupling reinforcement body is a foam, and the foam is a rigid polyurethane foam or a phenolic foam.

[0013] Optionally, the configuration reinforcement body is a tubular body in a hollow tubular configuration, and the hollow tubular configuration is one of a thin-walled circular tube, a corrugated tube or a bellows.

[0014] Optionally, the length of the hollow tubular configuration is 1.5-10mm, and the single-layer wall thickness of the hollow tubular configuration is 0.05-0.5mm; the height of the integrated composite core is 5-30mm.

[0015] Optionally, the hollow tubular configuration further includes a multi-layer nested tubular configuration.

[0016] Optionally, the configuration reinforcement body is a wave-leaf-shaped configuration reinforcement body, and the wave-leaf-shaped configuration reinforcement body includes a U-shaped, V-shaped or Z-shaped corrugated sheet.

[0017] Optionally, the configuration reinforcement body is a star-shaped configuration reinforcement body with a radial cross section, or a frame-shaped configuration reinforcement body with a cross section of a cross shape.

[0018] Optionally, the honeycomb cell is made of a metal material, and the honeycomb cell is made of an aluminum alloy, stainless steel or titanium alloy.

[0019] Optionally, the honeycomb cell is made of a composite material, and the honeycomb cell is made of a Nomex material, a carbon fiber reinforced resin or a glass fiber reinforced resin.

[0020] Optionally, the configuration reinforcement body is made of an aluminum alloy, stainless steel or titanium alloy; or the configuration reinforcement body is made of a carbon fiber reinforced thermoplastic or thermosetting plastic.

[0021] The application also provides a three-phase mutual coupling multi-directional synergistically enhanced composite honeycomb energy absorption device, comprising the three-phase mutual coupling multi-directional synergistically enhanced composite honeycomb structure.

[0022] In the application, the composite honeycomb energy absorption structure significantly improves the mechanical properties: through the three-phase mutual coupling of the honeycomb matrix, the configuration enhancer and the interface coupling enhancer, the load bearing and energy absorption capacity of the honeycomb structure in the out-of-plane direction is significantly enhanced, effectively breaking through the performance bottleneck of the traditional honeycomb structure caused by the wall thickness, material properties and single deformation mode. At the same time, in the in-plane direction, the performance deficiency of the honeycomb structure is greatly made up, and through the synergistic effect of the configuration enhancer and the interface coupling enhancer, the strength, stiffness and energy absorption capacity of the honeycomb structure under in-plane compression, shear and other loads are significantly improved. Experimental verification shows that the improvement range of mechanical properties under specific specifications can exceed 1000%, so that the honeycomb structure can better adapt to multi-directional complex stress working conditions, and greatly widen its application field.

[0023] In the application, the configuration enhancer can be flexibly designed according to performance requirements, and is no longer limited to the traditional thin-walled pipe, but can adopt various forms such as hollow tubular, wave sheet, star-shaped and frame-shaped, thereby providing greater freedom for structure design and meeting the high-performance customized demand in different application scenarios. In the manufacturing process, the stable coupling and integrated forming between the honeycomb matrix and the configuration enhancer are realized through the in-situ foaming and curing of the foam, thereby simplifying the process flow, reducing the requirement for the size precision of the material, not requiring perfect tangency between the components, greatly reducing the manufacturing difficulty and cost. In addition, the preparation process of the application does not need to rely on high-cost equipment, and can realize automatic and modular operation, thereby improving the production efficiency, showing good industrial implementability, and having significant economic benefits and application prospect. BRIEF DESCRIPTION OF DRAWINGS

[0024] In order to more clearly illustrate the technical solutions of the embodiments of the application, the following will briefly introduce the drawings needed to be used in the description of the embodiments of the application. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creating any inventive labor.

[0025] Figure 1 is the overall structure diagram of the three-phase mutual coupling multi-directional synergistically enhanced composite honeycomb structure in an embodiment of the application;

[0026] Figure 2 is the exploded structure diagram of the three-phase mutual coupling multi-directional synergistically enhanced composite honeycomb structure in an embodiment of the application;

[0027] Figure 3It is the embedded structure diagram of the configuration reinforcement of the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure in an embodiment of the present application;

[0028] Figure 4 It is the specific structure schematic diagram of the configuration reinforcement of the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure in an embodiment of the present application;

[0029] Figure 5 It is the working effect diagram of the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure in an embodiment of the present application when bearing out-of-plane load;

[0030] Figure 6 It is the working effect diagram of the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure in an embodiment of the present application when bearing in-plane load;

[0031] Figure 7 It is the preparation process flow chart of the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure in an embodiment of the present application;

[0032] Figure 8 It is the connection schematic diagram of the interface coupling reinforcement and the configuration reinforcement when the interface coupling reinforcement is foam in an embodiment of the present application.

[0033] The reference signs in the description are as follows:

[0034] 1-honeycomb matrix, 11-honeycomb cell, 111-cell, 2-configuration reinforcement, 3-interface coupling reinforcement. DETAILED DESCRIPTION

[0035] In order to make the technical problems solved by the present application, the technical solutions and beneficial effects clearer, the present application will be further described in detail below with reference to the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application, and are not used to limit the present application.

[0036] In the description of the present application, it should be understood that the orientation or positional relationship indicated by the terms "longitudinal", "radial", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In the description of the present application, unless otherwise specified, the meaning of "a plurality of" is two or more.

[0037] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connecting" should be understood in a broad sense, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through intermediate medium, or the internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0038] As Figures 1 to 8 shown, an embodiment of the present application provides a three-phase mutual coupling multi-directional synergistic enhanced composite honeycomb structure, comprising:

[0039] A honeycomb base body 1, which is composed of a plurality of closely and regularly arranged polygonal three-dimensional honeycomb cells 11, each of which has a cell 111.

[0040] A configuration enhancer 2 with a three-dimensional geometric gap configuration, the length of the configuration enhancer 2 is equal to the length of the honeycomb cell 11, and the cross-sectional profile of the configuration enhancer 2 is smaller than the inscribed circle of the cell 111 of the honeycomb cell 11; the configuration enhancer 2 is embedded in all the cells 111, or embedded in part of the cells 111 according to a regular layout.

[0041] An interface coupling enhancer 3, which is filled in the gap between the inner wall of the cell 111 and the configuration enhancer 2 by in-situ foaming and curing, and all the gaps of the configuration enhancer 2 itself, forming a continuous multi-phase interface. Among them, the honeycomb base body 1, the configuration enhancer 2 and the interface coupling enhancer 3 constitute a three-phase mutual coupling integrated composite core through the multi-phase interface.

[0042] Understandably, a plurality of honeycomb cells 11 are regularly arranged and closely connected to form a honeycomb base body 1 with continuous structure, and the specific arrangement can be set according to the requirements. The cross section of the honeycomb cell 11 can be regular hexagon, square or other shapes, each of the honeycomb cells 11 has the same height, length and single-layer wall thickness, thereby forming a honeycomb base body 1 with a lightweight continuous base skeleton with consistent out-of-plane height and uniform in-plane distribution. Each of the honeycomb cells 11 has a cell 111, which provides an embedding space for internal components. The configuration enhancer 2 can have various forms, and its core requirement is to have a thin-walled structure and a three-dimensional geometric gap. As Figure 3As shown, as long as the feature size of each configuration reinforcement 2 is smaller than the inscribed circle size of the cell 111 of the honeycomb matrix 1, it can be filled into the inside of the cell 111 of the honeycomb matrix 1 to meet the basic requirements. The configuration reinforcement 2 does not need to be completely inlaid in the honeycomb matrix 1, nor does it need to be in direct contact with the inner wall of the cell 111 of the honeycomb matrix 1, because the coupling relationship between the two is realized through the interface coupling reinforcement (foam). Understandably, the configuration reinforcement 2 and the honeycomb matrix 1 are highly consistent in the out-of-plane direction, ensuring that the configuration reinforcement 2 of the entire composite core is highly uniform in the out-of-plane direction. The distribution of the configuration reinforcement 2 inside the honeycomb matrix 1 is flexible, and it can be distributed in all cells 111 or in part of the cells 111 according to certain rules.

[0043] In an embodiment, as shown in Figure 8 The interface coupling reinforcement 3 is a foam, which is a rigid polyurethane foam or a phenolic foam. Understandably, after the configuration reinforcement 2 is embedded in the cell 111 of the honeycomb matrix 1, a liquid combined blowing agent is injected into the inside of the composite core to foam and expand in situ; in order to avoid the configuration reinforcement 2 from being deviated in the height direction due to expansion during the foaming process, a small amount of pre-foaming is first performed at the bottom of the structure to preliminarily fix the position; then, before the blowing agent is completely cured, the position of the configuration reinforcement 2 is further locked through physical pressing in the out-of-plane direction to ensure its height consistency; on this basis, a sufficient amount of blowing agent is injected to complete the overall foaming, so that the interface coupling reinforcement (foam) 3 fully fills all the gaps between the cell walls of the cell 111 of the honeycomb matrix 1 and the surface of the configuration reinforcement 2 and the internal voids, forming a continuous multiphase interface; finally, the interface coupling reinforcement 3 realizes the integration and curing of the composite structure through geometric fitting and physical bonding. The material of the interface coupling reinforcement 3 is preferably a rigid polyurethane foam or a phenolic foam, which needs to have sufficient strength and rigidity, and a normal temperature or high temperature foaming forming process is adopted to adapt to the mass production demand.

[0044] In an embodiment, as shown in Figures 1 to 4 The configuration reinforcement 2 is a tubular body in a hollow tubular configuration, which is one of a thin-walled circular tube, a corrugated tube, and a bellows.

[0045] In an embodiment, as shown in Figures 1 to 4 The length of the hollow tubular configuration tube is 1.5-10 mm, and the single-layer wall thickness of the hollow tubular configuration tube is 0.05-0.5 mm; the height of the integrated composite core is 5-30 mm. Understandably, the size of the hollow tubular configuration tube can be flexibly adjusted according to the use scenario, for example, in a load-bearing sandwich layer, an aluminum alloy composite core with a height of the integrated composite core of 10 mm, a length of the honeycomb cell 11 of 2.75 mm, and a single-layer wall thickness of the hollow tubular configuration tube of 0.05 mm can be selected.

[0046] In an embodiment, as shown in Figure 4 the hollow tubular configuration pipe body further comprises a multi-layer nested tubular configuration pipe body.

[0047] Understandably, in a specific implementation, when the configuration enhancer 2 is a hollow tubular configuration pipe body, the working principle of the three-phase mutually coupled multi-directional synergistically enhanced composite honeycomb structure is as follows:

[0048] As shown in Figure 5 under the action of out-of-plane compression load, the three-phase composite core material realizes a comprehensive breakthrough in performance through a multi-level synergistic mechanism: the honeycomb matrix 1 as a continuous skeleton first bears the main load path, and the hole wall of the cell 111 gradually buckles and collapses (a stable platform stage of plastic folding is formed), absorbing a large amount of basic energy and providing initial strength and stiffness support for the overall structure; at the same time, the configuration enhancer 2 is effectively restrained from Euler instability and local bending deformation under the double constraints of physical limitation of the honeycomb cell 11 hole wall and interface reaction force of the foam, and instead cooperates with the honeycomb hole wall to form a high-order folding structure (such as an axisymmetric folding mode), significantly improving the local compressive strength and energy dissipation efficiency; the foam material that works simultaneously realizes three functional couplings through in-situ foaming and curing: filling the gap between the honeycomb cell 11 and the hollow tubular configuration pipe body to eliminate the cavity invalid space (geometric fitting), forming a continuous interface to realize three-phase load transfer (physical bonding), and gradually densifying itself during compression to continuously absorb energy, while restraining the inefficient folding of the honeycomb wall and the lateral displacement of the thin wall of the hollow tubular configuration pipe body through interface reaction force, further improving the deformation stability of the two; finally, the three-phase components establish a multi-path load transfer mechanism through stable geometric fitting relationship, showing a significant synergistic enhancement effect; the out-of-plane strength, stiffness and energy absorption capacity of the composite core material are all superior to those of traditional honeycomb structures and simple superposition of each component material, and the key mechanical performance indicators are significantly superior to those of simple superposition of each unit material due to the multi-phase coupling effect.

[0049] As shown in Figure 6As shown, currently there are few technical solutions that can fully improve the out-of-plane performance of the honeycomb structure while also greatly enhancing the in-plane performance of the honeycomb. The three-phase composite core material significantly improves the load-bearing and energy-absorbing capacity of the honeycomb structure in the in-plane direction. Specifically, in the initial loading stage, the configuration enhancer 2 (hollow tubular configuration tube body) forms discontinuous regular rigid supports in the in-plane direction of the honeycomb structure under the constraint of the foam curing, effectively improving the overall strength and stiffness of the structure. As the load increases into the plastic large deformation stage, the configuration enhancer 2 (hollow tubular configuration tube body) is limited by the honeycomb hole wall and the foam, and according to the designed different configurations, it realizes controlled bending, folding, and even folding, etc. deformation, forming a sustainable in-plane deformation mode. In this process, the foam is continuously compressed and densified between the thin wall of the hollow tubular configuration tube body and the honeycomb, not only absorbing energy, but also further stabilizing and delaying the structural instability behavior of the honeycomb and the thin wall of the hollow tubular configuration tube body. The synergistic effect of the hollow tubular configuration tube body and the foam greatly makes up for the deficiency of the in-plane performance of the honeycomb itself. Experimental verification shows that the improvement of mechanical properties exceeds 1000%.

[0050] The working principle of the honeycomb structure of the present application is not limited to the application of the thin-walled circular tube type configuration enhancer 2 (hollow tubular configuration tube body). The working principle of the honeycomb structure of other configuration enhancer 2 can be similarly obtained.

[0051] In an embodiment, as shown in Figure 4 The configuration enhancer 2 is a folded sheet configuration enhancer, which includes U-shaped, V-shaped or Z-shaped corrugated sheets.

[0052] In an embodiment, as shown in Figure 4 The configuration enhancer 2 is a star-shaped configuration enhancer with a radial cross section, or a frame-shaped configuration enhancer with a cross-shaped cross section.

[0053] As shown in Figure 4 The configuration of the configuration enhancer 2 of the present application has high flexibility and is no longer limited to traditional thin-walled circular tubes. It can be designed flexibly according to performance requirements. The hollow tubular configuration (such as thin-walled circular tube, folded tube, corrugated tube, etc.) has simple structure and mature processing technology. In the out-of-plane direction, the strength, stiffness and energy absorption capacity of the structure are effectively improved through axial buckling and folding. In the in-plane direction, the radial support enhances the mechanical properties, and is suitable for occasions where the out-of-plane performance is the main performance and the cost and process adaptability requirements are higher. If necessary, the hollow tubular configuration can be further developed into a multi-layer nested tubular configuration, that is, a plurality of concentric tubes with the same or different properties are embedded in a single honeycomb cell, realizing staged buckling and folding in the out-of-plane direction, thereby producing a step energy level effect. The multi-layer nested tubular configuration can also form greater radial stiffness and more complex damping channels in the in-plane direction.

[0054] Understandably, the corrugated sheet configuration can adopt U-shaped, V-shaped, Z-shaped and other corrugated or corrugated sheets, which are low in cost and flexible in layout. In the out-of-plane direction, it presents similar controllable folding energy absorption characteristics as the tubular configuration, while in the in-plane direction, it also has good transverse support effect. The star-shaped configuration and the frame configuration use a radiating cross-section or a frame to build a multi-directional support network. In addition to enhancing the out-of-plane performance, it can form a multi-path load transfer mechanism in the in-plane direction, significantly improving the in-plane mechanical performance of the structure, and is suitable for complex service environments that bear multi-directional coupled loads. In addition, more complex shaped components can also be manufactured through 3D printing to meet the needs of customized core material design with high performance.

[0055] In an embodiment, the honeycomb cells 11 are made of metal materials, the honeycomb cells 11 are made of aluminum alloy, stainless steel or titanium alloy; or the honeycomb cells 11 are made of composite materials, the honeycomb cells 11 are made of Nomex material, carbon fiber reinforced resin or glass fiber reinforced resin. Understandably, the mass production of the honeycomb base 1 usually adopts two mainstream process routes: one is that the sheet material (such as metal foil or composite foil) is first folded into a honeycomb prototype, and then fixed by bonding to complete the shaping; the second is that the sheet material is first connected in a laminated or butt joint manner to form a solid honeycomb block, and then the honeycomb shape is formed through a stretching and unfolding process and finally shaped. Although the two process routes have different step-by-step operations, the geometric characteristics (such as the arrangement of the honeycomb cells 11, the cell size, etc.) of the final product are completely consistent, and they are all common honeycomb structure manufacturing methods in large-scale production. It is worth noting that during the above processing, according to the difference of the sheet material stacking method or the stretching process parameters, the honeycomb base 1 can form a structure distinction of single-layer wall (single-layer sheet directly formed) or double-layer wall (formed after multiple layers of sheet material are stacked), to meet the differentiated needs of lightweight and strength in different application scenarios.

[0056] In an embodiment, the configuration enhancer 2 is made of aluminum alloy, stainless steel or titanium alloy; or the configuration enhancer 2 is made of carbon fiber reinforced thermoplastic or thermosetting plastic. Understandably, the configuration enhancer 2 can be made of metal materials such as aluminum alloy, stainless steel or titanium alloy, or made of composite materials such as carbon fiber reinforced thermoplastic or thermosetting plastic. These materials can be mass-produced through mature processes such as drawing, stamping, winding and molding. For configuration enhancers 2 with complex shapes and high functional requirements, they can be produced by means of wire cutting or additive manufacturing (3D printing). Finally, the configuration enhancer 2 can also be precisely embedded into the honeycomb through mechanical control.

[0057] In an embodiment, as shown in Figure 7 The manufacturing process of the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure is as follows:

[0058] According to design requirements, the configuration enhancer 2 is embedded in some or all of the cells 111, liquid combined foaming agent is injected into the structure combined by the honeycomb matrix 1 and the configuration enhancer 2, a small amount of pre-foaming is carried out at the bottom of the structure, the position of the configuration enhancer 2 is fixed in the out-of-plane direction through physical pressing, on the basis of pre-foaming positioning, sufficient foaming agent is injected to make it in-situ foam and expand between the honeycomb matrix 1 and the configuration enhancer 2. After the foaming agent is solidified, the interface coupling enhancer (foam) 3 is in full contact with the cell walls of the honeycomb matrix 1 and the surface of the configuration enhancer 2, a stable multi-phase interface is formed, and finally the honeycomb matrix 1 and the configuration enhancer 2 are filled with all gaps and internal voids in the form of geometric embedding, and the foam also acts as an adhesive to realize stable coupling and integration of the three after complete solidification.

[0059] The application also provides a three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb energy absorption device comprising the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure. In the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb energy absorption device of the above-mentioned embodiment of the application, the three-phase mutual coupling multi-directional synergistic reinforced composite honeycomb structure comprises a honeycomb matrix 1 composed of a plurality of closely and regularly arranged polygonal three-dimensional honeycomb cells 11, each of which has a cell 111. A configuration enhancer 2 has a three-dimensional geometric gap configuration, the length of the configuration enhancer 2 is equal to the length of the honeycomb cell 11, and the cross-sectional profile of the configuration enhancer 2 is smaller than the inscribed circle of the cell 111 of the honeycomb cell 11; the configuration enhancer 2 is embedded in all the cells 111 or embedded in part of the cells 111 according to a regular layout. An interface coupling enhancer 3 is filled in the gap between the inner wall of the cell 111 and the configuration enhancer 2 and the entire gap of the configuration enhancer 2 through in-situ foaming and solidification, forming a continuous multi-phase interface. Among them, the honeycomb matrix 1, the configuration enhancer 2 and the interface coupling enhancer 3 constitute a three-phase mutual coupling integrated composite core through the multi-phase interface.

[0060] It is understandable that although there are methods in the prior art to fill thin-walled tubes into the honeycomb to enhance performance, such methods have obvious limitations. Due to the lack of solid connection and coupling between components, only tubes similar in shape to the honeycomb cells 111 can be selected to achieve shape matching, and the outer wall of the tube is required to be tangent to the inner wall of the honeycomb as much as possible, which makes the material size and process requirement extremely high, greatly increasing the manufacturing difficulty and cost. In contrast, the present application realizes stable solid connection between components through the three-phase coupling of honeycomb cells 11, foam and embedded thin-walled components (such as hollow tubular configurations), forming an integrated core material. This design allows the tube to be filled into the honeycomb as long as it can be embedded and fixed by the foam without perfect tangency, greatly simplifying the process difficulty. In addition, the embedded tube in the prior art is not fixed in the honeycomb, so it usually needs to be sealed in a larger structure for use, cannot be used independently, and can only consider the performance enhancement effect in the out-of-plane direction. The present application realizes solid connection and coupling between all components, can be used as an independent core material, and has significantly improved performance in both in-plane and out-of-plane directions, greatly expanding its application field.

[0061] The present application also fully considers cost control and industrial implementability in material selection and process design. The honeycomb base part, aluminum honeycomb and Nomex honeycomb have realized large-scale, low-cost commercial manufacturing. For the configuration enhancer 2, the material is selected from easily accessible metal or fiber reinforced composite materials, which not only can be easily mass-produced (such as hollow tubular, corrugated sheet, etc.), but also can meet the low-cost customization demand (such as star-shaped, frame-shaped, etc.). In addition, the foam material uses polyurethane, phenolic and other foaming materials, which have low raw material cost and mature process, and can be directly injected and foamed under medium and low temperature conditions to realize in-situ co-forming with the honeycomb and embedded components. Overall, the preparation process of the present application does not need to rely on high-cost equipment, and can realize automatic and modular operation, thereby realizing the simplicity of production process, the low cost of raw materials and the high efficiency of manufacturing efficiency, and showing significant advantages.

[0062] The present application successfully constructs a new type of composite core material structure of three-phase synergistic reinforcement of honeycomb cell 11-configuration enhancer 2-foam by embedding configuration enhancer 2 inside the honeycomb structure and combining with foam material in-situ filling. This structure exhibits significant advantages in multiple aspects: on the one hand, it significantly enhances the load-bearing and energy-absorbing capacity of the honeycomb in the out-of-plane direction; on the other hand, it effectively makes up for the serious deficiency of the honeycomb in the in-plane direction, so that it performs well in multi-directional stress working conditions. In addition, the configuration of the thin-walled member (configuration enhancer 2) can be flexibly customized according to performance requirements, and the foam filling realizes efficient limiting and interface coupling, ensuring that the three form a stable load transmission and energy dissipation system during deformation. The structural design of the present application is ingenious, the production process is simple, and the cost is low, which can fully cope with multi-directional complex load working conditions, has good engineering adaptability and application prospect, and is expected to be widely used in the fields of aerospace, rail transportation, automobile engineering and the like.

[0063] The above-described embodiments are only used to illustrate the technical solutions of the present application, rather than limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application, and should be included in the protection scope of the present application.

Claims

1. A three-way mutually coupled multi-directional synergistically enhanced composite honeycomb structure, characterized in that, include: The honeycomb substrate (1) is composed of multiple closely and regularly arranged polygonal three-dimensional honeycomb cells (11), each of which has a pore (111). The configuration reinforcement (2) has a three-dimensional geometric gap configuration. The length of the configuration reinforcement (2) is equal to the length of the honeycomb cell (11), and the cross-sectional profile of the configuration reinforcement (2) is smaller than the inscribed circle of the pores (111) of the honeycomb cell (11). The configuration reinforcement (2) is embedded in all the pores (111), or embedded in some of the pores (111) according to a regular layout. The interface coupling reinforcement (3) fills the gap between the inner wall of the pore grid (111) and the configuration reinforcement (2), as well as all the gaps of the configuration reinforcement (2) itself, through in-situ foaming and curing, to form a continuous multiphase interface; The honeycomb matrix (1), the configuration reinforcement (2), and the interface coupling reinforcement (3) form a three-phase coupled integrated composite core through the multiphase interface.

2. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 1, characterized in that, The interface coupling reinforcement (3) is a foam, which is a rigid polyurethane foam or a phenolic foam.

3. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 1, characterized in that, The configuration reinforcement (2) is a tube with a hollow tubular configuration, which is one of a thin-walled round tube, a zigzag tube, or a corrugated tube.

4. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 3, characterized in that, The length of the hollow tubular structure is 1.5-10mm, and the single-layer wall thickness of the hollow tubular structure is 0.05-0.5mm; the height of the integrated composite core is 5-30mm.

5. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 3, characterized in that, The hollow tubular structure also includes a multi-layered nested tubular structure.

6. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 1, characterized in that, The configuration reinforcement (2) is a corrugated plate-shaped reinforcement, which includes U-shaped, V-shaped or Z-shaped corrugated sheets.

7. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 1, characterized in that, The configuration reinforcement (2) is a star-shaped reinforcement with a radial cross section, or a frame-shaped reinforcement with a grid-shaped cross section.

8. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 1, characterized in that, The honeycomb cell (11) is made of metal, specifically aluminum alloy, stainless steel, or titanium alloy. Alternatively, the cell (11) may be made of a composite material, such as Nomex material, carbon fiber reinforced resin or glass fiber reinforced resin.

9. The three-way mutually coupled multi-directional synergistic enhancement composite honeycomb structure according to claim 3, characterized in that, The configuration reinforcement (2) is made of aluminum alloy, stainless steel or titanium alloy; or the configuration reinforcement (2) is made of carbon fiber reinforced thermoplastic or thermosetting plastic.

10. A three-way mutually coupled multi-directional synergistic enhancement composite honeycomb energy absorption device, characterized in that, Including the three-way mutually coupled multi-directional synergistic enhancement composite cellular structure as described in any one of claims 1-9.

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